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PT. PERTAMINA GAS

PT. PATRA DRILLING CONTRACTOR

PEMBANGUNAN PIPA GAS DIAMETER 16”

SEPANJANG 8100 METER SEMARE- TIE IN PIPA
PORONG GRATI

GAS IN DAN COMMISSIONING PROCEDURE

DOC NO : PG-PDC-MP-SM-PRO-010

2 04-12-‘17 Re-Approved for Construction MN AF KK

1 29-11-‘17 Re-Approved for Construction MN AF KK
0 06-11-‘17 Approved for Construction MN FD KK
B 20-10-‘17 Issued for Approval MN FD KK
A 06-10-‘17 Issued for Review MN FD KK
PREP’D CHK’D APP’D APP’D
REV DATE DESCRIPTION
PT. PDC PERTAGAS

TABULATION OF REVISION SHEET

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REVISION REVISION
SHEET REMARKS SHEET REMARKS
A B C D E F
1 1
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12 12
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15 15
16 16
17 17
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TABLE OF CONTENT
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REVISION SHEET 1
TABLE OF CONTENT 2
1. GENERAL 3
1.1 Project Description 3
1.2 Objective 3
1.3 Definition 3
1.4 Codes & Standard 3
1.5 Abbreviation 4
2. RESPONSIBILITIES 4
3. GENERAL PRE-REQUISITES 6
3.1 Safety Preparedness 6
3.2 Mechanical Completion 7
3.3 Availability of Equipment, Tools, Consumables and Other Materials 7
4. DOCUMENT COMPLETION 7
5. COMMISSIONING PROCEDURE 8
5.1 Preparation for Gas in8
5.2 Commissioning Step 8
6. PROVIDE SPARE PART EQUIPMENT OR UTILITIY 12
7. ACCEPTANCE CRITERIA 12
8. ATTACHMENT 13
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1. GENERAL
1.1 Project Description
PT Pertamina Gas intends to build new gas pipeline from Semare station,
which have two tie in point from Isargas Metering and Parnaraya Metering, to
Porong Grati Future Connection Station which has tie into existing pipe line Porong
Grati. The pipeline is about 8100 meter will be completed with piq launcher and piq
receiver.

1.2 Objective
The objective of this document is to guide the preparation and activity of
Commissioning for project "Pembangunan pipa gas diameter 16” sepanjang 8100
meter Semare – tie in pipeline Porong Grati” and ensure that all pipeline, valve and
accesories system are fully tested and commissioned.

1.3 Definition

PROJECT Pembangunan Pipa Gas Diameter 16” Sepanjang 8100

meter Semare- Tie in Porong Grati.
CLIENT PT. PERTAMINA GAS (PERTAGAS) as The Project Owner.

CONTRACTOR PT. PATRA DRILLING CONTRACTOR (referred as PDC)

for Piping & Pipeline.
VENDOR/ Refers to the company selected by COMPANY or
MANUFACTURER CONTRACTOR, which is responsible for the purchase
agreement specification.
MIGAS
Indonesian Government body which is responsible for
issuing licenses and permits oil and gas facilities.

1.4 Codes & Standard

ASME B31.8 Gas Transmission and Distribution Piping System (ed. 2010).
ASME B31.3 Process Piping.
ASME B16.5 Pipeline Flanges and Fittings.
ASME B16.9 Factory Made Wrought Steel Butt Welding Inductions Bends
for Transportation and Distribution System.
ASME VIII Div.1 Rules for Construction of Pressure Vessel
AGA- 8 Compressibility Factors of Natural Gas
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AGA- 9 Measurement of Gas by Multipath Ultrasonic Meters

NFPA 704 Standard System for the Indentification of the Hazard of
Materials for Emergency Response.
OHSAS 18001 Occupational Health & Safety Zone

1.5 Abbreviation

QA / QC Quality Assurance / Quality Control

HSE Health & Safety Environment
LOTO Log Out Tag Out
ERT Emergency Response Team
ERP Emergency Response Plan

2. RESPONSIBILITIES
Project Manager Shall be responsible for all activities
Construction Manager Shall report to the Project Manager. Shall be responsible for
construction activities related to this procedure, and shall
coordinates with the QA/QC Manager, HSE Manager Supervisor
for implementation of this procedure.

QA/ QC Manager Shall report to the Project Manager. Shall be responsible for
overall quality matters described in this procedure
activities, conform to Procedure, Codes/ Standards.

HSE Manager Shall report to the Project Manager. Shall be responsible for
HSE performance and where QA necessary initiating
corrective action through line management.

HSE Coordinator Shall report to HSE Manager, Monitoring the safety of all
working practices. Coordinating with Employer supervisor for
all activities. Introduce implementation of HSE plan and
procedure to all personnels. Coordinating and monitoring all
activities accordingly in safety manners. Prepare emergency
response plans and mitigation of hazards equipment.

QC Inspector Shall eport to QA/QC Manager. Shall responsible for the

performance of inspection to ensure all of activity conforms to
Procedures, Standard/Codes and make reporting.
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HSE Inspector Shall report to HSE Coordinator. Prepare Job Safety Analysis
(JSA). Perform safety briefing at site. Controlling and observing
of vehicle at work site. Perform routing check gas with gas
detector.

Supervisor Ensuring that the work permit are carried out. Familiarizing
himself and his operators, with the details of the overall
procedure including Welding Procedures, Tapping Procedures.
Coordinating with Employer supervisor for all activities.
Ensuring all personnel involved, understand of procedures and
scope of work and all materials comply with specification.
Supervise all activities of leakage test and gas in and make
sure working properly. Prepare equipment, worker and work
plan. Schedulling and controlling activities and ensuring on
time completion according to plan. Report all activities of
leakage test and gas in to Construction Manager.

Instrument Engineer Supporting and assisting Supervisor. Providing technical

assistance and problem solving for a wide range of
instrumentation system as well as assisting with detailed
design. Partisipate in control and instrumentation construction,
meeting and troubleshooting activities. Provides engineering
information and evaluate instrumentation system by answering
question and request. Contributes to team effort by
accomplishing related results as needed. Completes project by
training and guidance technicians.

System Integrator Supporting and assisting Supervisor. Configure and

programming of flow computer. Ensure communication and
interface between field instrument and flow computer - HMI
running well accordance with Employer regulation. Perform
calibration of metering equipment (flow comp and transmitter).
Validation of measurement instrument such as flowcomp,
transmitter. Perform report of commissioning.

Leader Commissioning Responsible for development of the commissioning program,

management of commissioning activities; systemization,
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planning, pre-commissioning, loop checking, leak testing,

introduction of chemicals, commissioning, start-up and
validation testing of the plant.

3. GENERAL PRE-REQUISITES

3.1 Safety Preparedness

Successful gas-in of Pipeline for "Pembangunan Pipa Gas diameter 16”

sepanjang 8100 meter Semare – Tie in Pipeline Porong Grati." project will depend
upon the results of careful checkout work performed prior to startup.
1) Area around semare station & future connection Porong grati station shall be
considered as a hazard area. Safety sign, barricade/ fence, flash light,
megaphone and displayed ERP, ERT, shall be put around that area.
2) Area around venting point shall be considered as a hazard area. Methane Gas
detection shall be provided. Temporary barricade or fence and safety sign
around venting point shall be provided during venting work.
3) Fire Truck, Portable Fire Extinguisher, Emergency Car, Ambulance and
Paramedic shall be provided at commissioning/ gas in activity.
4) Before system can be operated, all fire protection and safety equipment must
be in place and operable. All personnel must be completely familiar with the
location and operation of the equipment.
5) Radio (handy talky) shall be provided for communication. Mobile telephone
shall be used at the outside of station fence.
6) Work permit (Hot/ Cold) shall be obtained from Area Authorizer.
7) Ensure all equipment and system are in proper working order and that the
complete unit is ready for operation.
8) Safety tag (LOTO device) shall be attached on all valves mentioning initial
alignment position (close or open).
9) Evacuation route for emergency shall be clear from any obstruction.
10) The minimum personnel protective equipment required for this procedure are:
 Safety Helmet
 Safety Boot (Steel toe footwear)
 Suitable gloves should be worn when handling hazardous materials or
contacting cold or hot surface (Heavy Duty Hand Gloves)
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11) Supporting documents for commissioning implementation shall be collected in

one file consists of in-principle licenses meters, all the report SAT or function
test and commissioning procedure.

3.2 Mechanical Completion

Before commissioning, all facilities shall be mechanically completed and

attained Certificate of Mechanical Completion from Employer. All pipeline
construction works, inspections and tests must be satisfactorily completed include
NDE, Hydrostatic Test, Drying and Purging with an inert gas as required. Mechanical
Completion also includes verification of reinstatement of all items after test, final
inspection and punch listing, verification of inspection and test records, etc.

3.3 Availability of Equipment, Tools, Consumables and Other Materials

The following items shall be available at site and ready to use.

 Equipment and tools required for tightening the flanges non-spark hammer, etc.
 Communication devices among station, handy talky to be used in hazard area
shall be checked by safety officer to ensure its conformity to safety regulation.
 Equipment for Personnel Protection and Safety.

Checklist for each pre-requisition item refer to Attachment-1 and detail of equipment,
tools and material refer to Attachment-2.

4. DOCUMENT COMPLETION
The following document items shall be submitted :
 Design Basis.
 Precommissioning check list.
 Start up & Shutdown procedure (normal Operation) for each equipment.
 Start up station Procedure.
 Normal Operation (station) Procedure.
 Shutdown station Procedure (normal & emergency condition).
 Manual Instruction & Trouble Shooting Procedure for each equipment.
 Emegency procedure.
 Pra-Startup Safety Review.
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5. COMMISSIONING PROCEDURE

5.1 Preparation for Gas

1. N2 purging activity for pipeline system, piping and metering are satisfactory
completed.
2. Function test for all electrical and instrument devices are finished and completed
with report.
3. All supporting device such as fire water (if any), fire fighting, F&G system are
already tested.
4. Pra-Startup Safety Review (PSSR) status is ready to gas in.
5. Each locations for commissioning area are already settled.
6. Check the record existing pressure ( supply from Isargas metering )
7. Ensure that the piping are filled with nitrogen gas to a minimum pressure of 0.5
barg.
8. Check readiness of pipeline to metering system to receive natural gas
9. Put Lock Out – Tag Out (LOTO) on all valves.
10. Team (contractor ) pre-comm & commisioning shall standby on site.
11. Check the completeness of tools (safety, electrical and instrumentation).
12. Spare part for commissioning (ex : gasket, etc), shall be well prepared.

5.2 Commissioning Step

No Action Remark
1 Safety Equipment
1.1 Personal Protective Equipment:
 Coverall/ Wearpack
 Safety Helmet
 Hand Glove
 Safety Glasses
 Ear Plug (If Necessary)
1.2 Baricade & Safety Sign
1.3 Gas Detector
1.4 Portable fire Extinguisher
1.5 Fire Truck & Fire Fighters tim (standby at Location)
1.6 Ambulance and medics (standby at Location)

2 Ensure Equipment Status at Each Location Before Gas in

2.1 Instrumentation:
 Ensure all instrumentation ( Pressure Indicator) have been calibrated and ready to used.
 Ensure Pig indicator is already checked and ready to be used
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2.2 Electrical:
 Electrical system has been checked and commissioned.
 All electrical equipment has been loop check (Tested).
 Electrical utilities preparation such as;
Solar Panel System/ electricl source temporary

2.3 Equipment:
 Ensure all equipment installed are ready to used.
 Ensure functionally of SDV has been tested and ready to used.
 Ensure Temporary vent is installed.
 All block valve is start up position.
2.4 Purging Procedure of Pipeline from Semare Station to Future Connection Porong-Grati
Station:
 Ensure all future connection valves connected to blind flanges/caps on piping in both
station.
 Put all valves on the position ready for commissioning as indicated at Attachment-3.
 Step by steps N2 Purging for Pipeline :
 Purging N2, Inject from valve 3/4”-BV-031 & 3/4”-BV-032 , with purity reach 99% and
dew point reach -200C until there is no O2 content in Piping system.
 Step 1, make sure valve with tag number 16”-BV-002, 16”-BV-009, 16”-BV-004, 16”-BV-
007, 16”-BV-008, 12”-BV-045, 12”-BV-046, 10”-BV-011, 10”-BV-012, 10”-BV-043, 10”-
BV-044, 10”-BV-005, 8”-BV-013 & 8”-BV-014 are closed (another 16” valve are open).
Make sure gas indicator detected N2 from 3/4”-BV-028 (make tee connection before PI-
001) & 3/4”-BV-039. For monitoring pressure from PI-001 & PI-005 (another 3/4” valve
are closed). So SDV-001 is closed.
 Start to purge pipeline.
 When N2 is fully charged with 50 psig pressure then hold for 15 minutes then check with
gas detector with O2 indication.
 Check O2 indication with gas detector, if more than 1 % it must be re-purged until the
O2 content is less than 1 %.
 Check and make sure that the dew point content is less than -20 °C.
 Ensure O2 content maximal 1% and nitrogen content minimum 99% and maintained the
minimum pressure at 2-3 barg until process gas in.
 Step 2, inject N2 from ¾” BV-040.
 When N2 is fully charged with 50 psig pressure then hold for 15 minutes then check with
gas detector with O2 indication from ¾” BV-027.
 Re-check and make sure that the dew point content is less than -20 °C and O2 content
is less than 1 %.
SCHEMATIC PURGING N2 PIPELINE
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3 Gas in for Pipeline System & Metering System

3.1 Set all personnel involved as per Attachment-5
3.2 Ensure actual operating pressure at inlet
3.3 Ensure all valves on the initial position condition as per Attachment-3 (Initial Position Before
Commissioning).
3.4 Ensure all flanges were tightened. All flange connection shall be isolated using masking tape
for leakage test purpose. Leak check shall be performed by using soapy fluid.
3.5 Gas In Procedure (step by Steps):
 Open SDV-001 inlet gradually 25%, 50% opening to avoid mixing gas with N2.
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 Step 1, make sure valve with tag number 16”-BV-002, 16”-BV-009, 16”-BV-004, 16”-
BV-007, 16”-BV-008, 12”-BV-045, 12”-BV-046, 10”-BV-011, 10”-BV-012, 10”-BV-043,
10”-BV-044, 10”-BV-005, 8”-BV-013 & 8”-BV-014 are closed (another 16” valve are
open). For monitoring pressure from PI-001 & PI-005 (another 3/4” valve are closed).
 realese N2 from valve with tag number 3/4”-BV-039
 N2 & methane (CH4)content at temporary vent (3/4”-BV-039) by using gas indicator.
 Parallel with this proses when raising pressure gradually, every step, check flange
connection and make sure no have leakage. If leakage happened, do the bolt
tightening until no leakage indication found.
 Next, If N2 content get 1 % and methane (CH4) content get 99% and the gas indicator
has shown 100 % LEL means N2 inside pipeline has run out and the gas in process is
succed. closed temporary vent 3/4”-BV-039.
 Install pressure indicator temporary at BV-039, and then setting opening percentage of
12”-BV-009 until temporary pressure indicator showing pressure 630 psi and less.
 Piping and Pipeline system gas in is complete.

OPENED Gradually 25%, SCHEMATIC GAS IN PIPELINE

50%,75% & 100%
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*See gas in procedure & attachments for details.

6. PROVIDE SPARE PART EQUIPMENT OR UTILITIY

Contractor resposible to provide and make sure the spart part equipment or utilities
can be used technically in Pre-commisioning and Commissioning stage. The spart part
shall deliver to company (PERTAGAS).

7. ACCEPTANCE CRITERIA
Commisioning is considered as completed if the following criteria are fulfilled:
1. Gas in :
a. CH4 contain in pipeline and metering system has reached minimum level
95%.
b. No leak is detected during gas delivery and pressurizing at 5%, 15%
25%, 50% and 100% of operating pressure.
2. Performance Verification :
a. Actual verification that the instrumentation has perform properly.
b. Actual verification that the gas filter has perform properly.
c. Actual verification that the valves have perform properly.
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8. ATTACHMENT
Attachment – 1 Pre-Requisition Check List
Attachment – 2 Equipment and Tools List
Attachment – 3 Valve Initial Final Position List
Attachment – 4 Commissioning Committee & Communication Plan
Attachment – 5 P& ID (purging & gas in)
Attachment – 6 Prosedur Pertolongan Pertama
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Attachment -1 Pre-Requisition Check List

COMMISSIONING PROCEDURE
Attachment – 1 PRE- REQUISITE CHECK LIST
No Description Status Remark
1 All piping are filled with nitrogen to a minimum 0.5 barg
2 All Instrumentation equipment has been calibrated and loop,
function, and sequential test have been performed.
3 All packing, media, and chemicals have been applied inside
equipment
4 All temporary equipment in the piping has been removed and has
been installed permanent equipment
5 All related documents: approved PFD/ P&ID, Commisioning
Procedures, Inspection Test Procedure, HSE procedures,proposed
commissioning team organization.
6 Check metering system are "Ready to Gas-in"
7 Area metering shall be considered as a hazard area. Safety signs,
barricade/fence, flash light, megaphone and displayed ERP, ERT,
shall be put around that area.
8 Area around venting point shall considered as a hazard area.
Methane gas detection shall be provided. Temporary barricade or
fence and safety sign around venting point shall be provided during
venting work.
9 Fire truck shall be provided at metering system.
10 Ambulances and paramedic shall be provided at metering system,
while emergency cars.
11 Portable fire extinguishers shall be provided for each metering
system
12 Mobile telephone and/or radio (handy talky) shall be provided for
communication. Mobile telephone shall be used at the outside of
metering fence.
13 Work permit shall be obtained from Area Authorizer.
14 Fire and evacuation drill shall be conducted prior of commissioning.
15 Ensure Basic Safety Training for all site personnel has been
conducted.
16 Joint safety patrol shall be performed daily by CONTRACTOR's
safety officer and the EMPLOYER safety office.
17 Regular tool box meeting shall be performed daily

19 Safety tag shall be attached on all valves mentioning initial alignment

position (close or open)
20 Non spark tools shall be provided
21 Evacuation routefor emergency shall be clear from any obstruction
22 Personel Protective Equipment such as wear pack etc. shall be
provided for commissioning personnel
23 First aid box shall be available for commissioning personnel.
24 SATand individual equipment test has been done.
25 In case of emergency, the ERP will follow ERP of metering system at
each team's respected location.
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Attachment -2 Equipment & Tools List

COMMISSIONING PROCEDURE
Attachment – 2 Equipment & Tools List
No Parameter PIC Location Quantity Status Remark
1 PPE HSE&S
a. Wear Pack HSE&S
b. Safety Helmet
c. Safety Shoes
d. Hand Gloves
e. Raincoat
2 Portable Fire Extinguisher HSE&S
3 Display ERP HSE&S
4 ERT HSE&S
5 Emergency Contact List HSE&S
6 Warning Tapes HSE&S
7 Portable Gas Detector HSE&S
8 First Aid Kit HSE&S
9 Warning Sign Box: AWAS ADA GAS DILARANG HSE&S
MEROKOK & MENYALAKAN API DISINI
10 Flag HSE&S
11 Megaphone HSE&S
12 Medic HSE&S
a. SCBA HSE&S
b. Stretcher HSE&S
c. Ambulance HSE&S
d. Nurse HSE&S
General Tools
13 Spare part & Consumables Constrc
a. Grease Gun
b. Cotton Bag
c. Bubble fluid
d. Masking Tape
14 Tool Set Constrc
15 Anti Spark Hammer Constrc
16 Open- End Wrench (Kunci Pas) Constrc
17 N2 Bottle Constrc
18 Handy Talky HSE&S
19 Ladder Constrc
20 Digital Camera (Image & Video) HSE&S
21 Genset + LIghting Constrc
22 Pad Lock- Mater Key HSE&S

Attachment -3 Valve Piping & Pipeline Initial Final Position List (By PDC)
Initial Posistion
No Valve Tag Number From Before On Progress Final Position Remark
ISARGAS METERING Commissioning

SEMARE STATION Open 25%, 100% Opened

50%,75%, 100%
1 3/4”-BV-040 CLOSED OPEN OPEN

2 3/4”-BV-027 CLOSED OPEN OPEN

3 10”-SDV-001 CLOSED OPEN/CLOSED OPEN

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4 10”-BV-011 CLOSED CLOSED CLOSED

5 10”-BV-012 CLOSED CLOSED CLOSED

6 10”-BV-043 CLOSED CLOSED CLOSED

7 10”-BV-044 CLOSED CLOSED CLOSED

8 16”-BV-001 OPEN OPEN OPEN

9 3/4”-BV-028 OPEN OPEN OPEN INSTAL PI-001

10 16”-BV-009 CLOSED CLOSED CLOSED

11 16”-BV-003 OPEN OPEN OPEN

12 16”-BV-002 CLOSED CLOSED CLOSED

13 3/4”-BV-031 CLOSED CLOSED CLOSED

14 3/4”-BV-032 CLOSED CLOSED CLOSED

15 8”-BV-013 CLOSED CLOSED CLOSED

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PIER STATION

1 3/4”-BV-028 OPEN OPEN OPEN INSTAL PI-005

2 16”-BV-004 CLOSED CLOSED CLOSED

3 16”-BV-005 OPEN OPEN OPEN

4 8”-BV-014 CLOSED CLOSED CLOSED

5 10”-BV-005 CLOSED CLOSED CLOSED

6 12”-BV-045 CLOSED CLOSED CLOSED

7 12”-BV-046 CLOSED CLOSED CLOSED

8 16”-BV-006 OPEN OPEN OPEN

9 16”-CKV-001 OPEN OPEN OPEN

10 16”-BV-007 CLOSED CLOSED CLOSED

11 16”-BV-008 CLOSED CLOSED CLOSED

12 3/4”-BV-039 CLOSED OPEN CLOSED Open till N2 is 0%

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Attachment -4 Commissioning Committee & Communication Plan

CONTRACTOR COMMUNICATION PLAN

SAFETY COORDINATOR COMM. MANAGER (contractor) COMM. MANAGER (company)

Name Name Name
Phone Phone Phone

COMM. COORDINATOR
Name
Phone

SAFETY INSPECTOR COMMISSIONING TEAM

Name Name

RED ZONE
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Attachment -5 P& ID (Purging & Gas in)

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Attachment -6 Prosedur Pertolongan Pertama